Sink design with dissimilar materials

ABSTRACT

A vanity basin or kitchen basin is made of upper and lower portions of two dissimilar materials. An inner basin is inserted into an outer basin and extends a portion of the way down. The outer basin is separately attached to the counter. The inner basin may be formed integral with the countertop. The inner basin mates with a receiving surface of the outer basin, and a seal may be formed between the inner and outer basins.

BACKGROUND OF THE INVENTION

The invention relates generally to kitchen sink and vanity basins, and more particularly to kitchen sink and vanity basins having upper and lower portions made of dissimilar materials.

Historically, the basins used in kitchens, bathrooms, and other applications have been made entirely out of one type of material throughout the basin. However, recently stainless steel basins have been fabricated into the lower half of solid surface kitchen basins. This two material design provides the durability of stainless steel on the major working surfaces of the sink while also providing an aesthetic design element of allowing the upper part of the basin to be made of a more attractive looking material, and also allowing the upper basin and counter to be fabricated together without a visible seam.

An example of this prior art basin design having two portions made of dissimilar materials is illustrated in FIG. 1. As shown, the basin is formed of an upper basin and a lower basin. The upper basin extends down from the solid counter surface or countertop which overlies the counter substrate. The upper basin and the countertop are made of similar materials, i.e. they can form an integral piece with a seamless connection. The lower basin, made of a different material, is joined to the upper basin at its lower edge. The top edge of the lower basin contacts the lower edge of the upper basin, and they are held together by any suitable means. For example, as shown, a mounting element is fastened to the outside surfaces of the upper and lower basins near the joint. The lower basin may have a small flange at its upper edge to assist in holding the two portions together.

The design illustrated in FIG. 1 has a number of disadvantages. The method of fabrication is very labor intensive. The abutting ends must be precisely fit together. The entire weight of the lower basin (and anything contained therein) is supported at the joint between the upper and lower basins.

Thus an improved design for a sink or vanity basin made of upper and lower portions of dissimilar materials is desired.

SUMMARY OF THE INVENTION

Accordingly it is an object of the invention to provide an improved design for a sink or vanity basin having upper and lower portions made of dissimilar materials.

The invention is a basin design having an outer basin and an inner basin that is inserted into the outer basin and extends a portion of the way down. The outer basin is separately attached to the counter. The inner basin may be formed integral with the countertop. The inner basin mates with a receiving surface of the outer basin, and may be fixed thereto to form a seal therewith. The effect is two different basin components connected together, i.e. the outer basin has a partial facade or inner lining on its upper portion.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

FIG. 1 is a cross-sectional view of a prior art two part basin.

FIG. 2 is a cross-sectional view of a two part basin according to the present invention.

FIGS. 3 and 4 are detailed views of a seal between the two parts of the basin of FIG. 2.

DESCRIPTION OF THE INVENTION

A basin 10 according to the invention is formed of an outer basin 12 and an inner basin 14 that is inserted into the inner basin 12 and extends a portion of the way down. The outer basin 12 is separately and independently attached to a support structure, e.g. to the counter substrate 16, typically to its under surface. Any suitable attachment means can be used, e.g. some combination of fasteners and adhesives. The inner basin 14 extends from and may be formed integral with the counter surface or countertop 18. Inner basin 14 may form a seamless joint with countertop 18. Outer basin 12 has a recessed upper portion 20 designed to receive the lower end of inner basin 14. Inner basin 14 fits tightly within or mates with recessed portion 20 of outer basin 12 so that the inner surface of inner basin 14 is flush with the adjacent inner surface of outer basin 12.

Generally, a seal is formed between inner basin 14 and outer basin 12 at the recessed portion 20, as shown in FIGS. 3 and 4, so that water will not permeate between the two elements. The end 22 of inner basin 14 contacts portion 24 of outer basin 12. A sealant is placed in the seam between inner basin 14 and outer basin 12 where the surfaces are in contact. The end 22 may merely contact the portion 24, as in FIG. 3, or a flange (or a plurality of posts) 26 extending from portion 24 may engage a corresponding groove (or a plurality of holes) 28 in end 22, as shown in FIG. 4, for better alignment and sealing.

Thus the upper basin 14 and the outer basin 12 are connected together to form the two part basin 10 having a continuous inner surface. The inner basin 14 forms a partial facade or inner lining on the upper portion of outer basin 12. Outer basin 12 is preferably made of stainless steel, but may also be made of any other suitable material, such as ceramic, steeled enamel, or cast polymer. The inner basin may be made of cultured marble, ceramic, or any other suitable material compatible with the countertop surface. While the basin as illustrated has vertical sides, the sides of the basin can also be sloping.

The basin design of the invention provides significant improvements over the prior art design. The bottom portion is no longer attached solely to the top portion of the basin, but is instead directly attached to the counter. Thus the design is much stronger and easier to fabricate.

Changes and modifications in the specifically described embodiments can be carried out without departing from the scope of the invention which is intended to be limited only by the scope of the appended claims. 

1. A basin, comprising: an outer basin made of a first material; an inner basin made of a second material and inserted into and extending a portion of the way down into the outer basin, and forming a continuous inner surface therewith.
 2. The basin of claim 1 wherein the outer basin and inner basin are separately attached to a counter.
 3. The basin of claim 1 further comprising a sealant between the outer and inner basins
 4. The basin of claim 1 wherein the outer basin is made of stainless steel, ceramic, steeled enamel, or cast polymer.
 5. The basin of claim 1 wherein the outer basin is made of stainless steel.
 6. The basin of claim 1 wherein the inner basin is made of cultured marble, ceramic, or any material of which an adjacent countertop is made.
 7. The basin of claim 1 wherein the inner basin forms a seamless junction with a countertop.
 8. The basin of claim 1 wherein the outer basin further comprises a recessed upper portion for receiving a mating end of the inner basin so that the inner surface of the inner basin is flush with the adjacent inner surface of the outer basin.
 9. The basin of claim 8 wherein the recessed upper portion of the outer basin contains a flange and the mating end of the inner basin contains a corresponding groove for receiving the flange.
 10. The basin of claim 8 wherein the recessed upper portion of the outer basin contains a plurality of posts and the mating end of the inner basin contains a corresponding plurality of holes for receiving the posts.
 11. A method of making a basin, comprising: mounting an outer basin formed of a first material on a support structure; inserting an inner basin made of a second material, and separately mounted to the support structure, a portion of the way into the outer basin to form a continuous inner surface therewith.
 12. The method of claim 11 further comprising forming a seal between the outer and inner basins.
 13. The method of claim 11 further comprising forming the outer basin of stainless steel.
 14. The method of claim 11 wherein the inner basin is inserted into the outer basin by providing a recessed upper portion in the outer basin for receiving a mating end of the inner basin so that the inner surface of the inner basin is flush with the adjacent inner surface of the outer basin. 